Light weight rain apparel

ABSTRACT

An article of apparel such as a rain jacket includes a composite fabric formed of a textile layer including a plurality of yarns, each yarn including five to twenty-five filaments having non-circular cross-sectional shapes and a sealing layer applied as a coating directly to the interior surface of the textile layer and having a thickness of about 10 micrometers to about 30 micrometers.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 62/910,793, filed on Oct. 4, 2019 and entitled“Light Weight Rain Apparel”, the disclosure of which is incorporatedherein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to articles of rain apparel and, inparticular, a rain jacket.

BACKGROUND OF THE INVENTION

Rainwear typically includes multiple layers laminated together utilizingadhesive. However, providing multiple layers adds to the weight of theapparel. In addition, moisture can become trapped between the layers,further increasing the apparel's weight (due to the water retention), aswell as causing a discomfort to the wearer. In addition, the trappedmoisture requires a period of time for the apparel to completely dry(i.e., for the moisture to escape or evaporate from the apparel) beforeit is used again.

It would be desirable to provide a suitable article of apparel thatsufficiently repels water, is lightweight, and inhibits or preventspick-up of moisture between and/or within layers of the apparel thusenabling a more rapid drying time of the article of apparel after use.

BRIEF SUMMARY OF THE INVENTION

An article of rain apparel as a rain jacket is formed partially orcompletely of a composite fabric including a textile layer and a sealinglayer. The textile layer comprises a plurality of yarns, each yarnincluding five to twenty five filaments, where each filament has across-sectional shape that is non-circular (e.g., polygonal). Each yarnin the textile layer may possess a denier ranging from about 20 to about50. The denier per filament of each yarn can range from about 2.0 toabout 4.0. The sealing layer is formed by coating a predetermined amountof flowable polymer such as polyurethane directly onto a surface of thetextile layer to form a continuous layer along the textile surface. Thepolymer is cured, resulting in a membrane having a thickness of about 10micrometers to about 30 micrometers.

The resulting article of apparel is lightweight, exhibits low moistureretention when exposed to water (e.g., when exposed to rain) as a resultof having a low void volume within the textile layer and at the boundarybetween the textile layer and the sealing layer, and further driesquickly (due to its low moisture retention).

In other embodiments, a method of forming a composite fabric comprisesapplying, via a coating process, a liquid or semi-solid material to asurface of a textile material so as to form a solid material sealinglayer directly on the textile material surface having a thickness ofabout 10 micrometers to about 30 micrometers. The textile materialcomprises a plurality of yarns, each yarn including five to twenty fivefilaments, where each filament has a cross-sectional shape that isnon-circular. In the method, the applying via a coating process cancomprise spreading the liquid or semi-solid material onto the surface ofthe textile and curing it to form a thin, first layer having a thicknessthat is less than 10 micrometers (e.g., about 3 micrometers), and thenapplying a thin, second layer of material onto the first layer ofmaterial, the second layer of material possessing a similar thickness(e.g., less than 10 micrometers and, in particular, about 3micrometers). Third and subsequent thin layers may be applied until thedesired thickness is achieved, thereby forming a layer of solid materialhaving a thickness of about 10 micrometers to about 30 micrometerscoating the surface of the textile layer.

The above and still further features and advantages of the presentinvention will become apparent upon consideration of the followingdetailed description of specific embodiments thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an example embodiment of an article of apparel (a jacketin accordance with embodiments described herein.

FIG. 2A depicts a cross-sectional view of an embodiment of a yarnincluding round and circular filaments.

FIGS. 2B, 2C and 2D depict cross-sectional views of example embodimentsof yarns including non-round filaments that can be used to form atextile layer as described herein.

FIGS. 3A and 3B each depicts a cross-sectional view of an exampleembodiment of an island-in-the-sea (INS) fiber that can be used to formone or more yarns in a textile layer as described herein.

FIGS. 4A, 4B and 4C are photographic images in magnification of aportion of a two layer structure in cross-section formed in a manner asdescribed herein.

FIG. 5 depicts a photographic image in magnification of a portion of atwo layer structure in cross-section consisting of a textile layer and afilm secured to the textile layer via dot lamination.

Like reference numerals have been used to identify like elementsthroughout this disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, reference is made to theaccompanying figures that form a part hereof wherein like numeralsdesignate like parts throughout, and in which is shown, by way ofillustration, embodiments that may be practiced. It is to be understoodthat other embodiments may be utilized, and structural or logicalchanges may be made without departing from the scope of the presentdisclosure. Therefore, the following detailed description is not to betaken in a limiting sense, and the scope of embodiments is defined bythe appended claims and their equivalents.

Aspects of the disclosure are disclosed in the accompanying description.Alternate embodiments of the present disclosure and their equivalentsmay be devised without parting from the spirit or scope of the presentdisclosure. It should be noted that any discussion herein regarding “oneembodiment”, “an embodiment”, “an exemplary embodiment”, and the likeindicate that the embodiment described may include a particular feature,structure, or characteristic, and that such particular feature,structure, or characteristic may not necessarily be included in everyembodiment. In addition, references to the foregoing do not necessarilycomprise a reference to the same embodiment. Finally, irrespective ofwhether it is explicitly described, one of ordinary skill in the artwould readily appreciate that each of the particular features,structures, or characteristics of the given embodiments may be utilizedin connection or combination with those of any other embodimentdiscussed herein.

Various operations may be described as multiple discrete actions oroperations in turn, in a manner that is most helpful in understandingthe claimed subject matter. However, the order of description should notbe construed as to imply that these operations are necessarily orderdependent. In particular, these operations may not be performed in theorder of presentation. Operations described may be performed in adifferent order than the described embodiment. Various additionaloperations may be performed and/or described operations may be omittedin additional embodiments.

For the purposes of the present disclosure, the phrase “A and/or B”means (A), (B), or (A and B). For the purposes of the presentdisclosure, the phrase “A, B, and/or C” means (A), (B), (C), (A and B),(A and C), (B and C), or (A, B and C).

The terms “comprising,” “including,” “having,” and the like, as usedwith respect to embodiments of the present disclosure, are synonymous.

As described herein, an article of apparel is formed that includes acomposite fabric comprising a textile layer and a sealing layer incontinuous contact with a surface of the textile layer, where thecomposite fabric minimizes (e.g., prevents) water penetration throughthe composite fabric as well as includes a structure that minimizesinterstices between yarns of the fiber and/or the interface/boundarybetween the sealing layer and the textile surface, thereby minimizing(e.g., substantially eliminating) water retention within the compositefabric, thus rendering the article of apparel suitable for use asraingear or other outdoor use that shields a user from getting wet andimproving overall dry time of the apparel.

As further described herein, the sealing layer (also called a waterprooflayer or waterproofing layer) is applied to the textile layer in amanner and also the textile layer comprises a suitable configuration ofyarns or filaments having suitable geometrical cross-sections or shapes,deniers and/or arrangements so as to reduce or minimize interstitialspacings or voids between the textile layer and the sealing layer aswell as interstitial spacings or voids between yarns and/or filamentswithin the textile layer, which in turn reduces or minimizesintroduction and/or retention of moisture/water within the textile layeror at a boundary between the textile layer and the sealing layer duringuse of the article of apparel. Such configuration further enhances thedrying performance (i.e., reduces drying time) of the article of apparelin comparison to other, conventional rain gear after being subjected toa wet environment (e.g., wearing of the article of apparel outside andbeing subjected to rain for a period of time).

Referring to FIG. 1, an article of apparel may be in the form of ajacket 102 that includes a main trunk or torso section 104, a hoodsection 106 that extends from an upper portion of the torso section andis configured to pull over and cover portions of the head of the wearer,and arm sleeve sections 108 extending transversely from opposing upperside portions (which correspond with the shoulders of the wearer) of thetorso section. The torso section 104 further includes a front side 110that corresponds with the chest and abdomen of the wearer and a rearside (not shown) that corresponds with the back of the wearer. Thejacket 102 can further include front pockets, a lengthwise extendingclosure member (e.g., a zipper) disposed at a central location along thefront side 110, as well as any other structural features suitable forits intended purpose.

At least a portion of the article of apparel 102 (e.g., one or all ofsections 104, 106, 108 of the jacket 102, as well as a portion 150 of ajacket section) is formed from a multilayer composite fabric 400including an outer textile layer 405 and an inner (user-facing) sealinglayer 420 (FIG. 4A). While FIG. 1 depicts section 150 at the torsosection 104, it is noted that section 150 can be located at anyportion(s) of the jacket 102 (e.g., at the hood section 106 or an armsleeve section 108) and/or can be used to form or define the entirejacket. In other words, the composite fabric as described herein can beused to form one or more portions or the entire structure of an articleof apparel or garment.

The textile layer 405 comprises a plurality of yarns combined in anysuitable manner, e.g., via weaving, knitting and/or a nonwoven process,so as to be imparted with suitable properties such as a suitablethickness, suitable drape, suitable textured feel, etc. The yarns can beformed from fibers or filaments that comprise any suitable naturaland/or synthetic polymer materials including, without limitation,polymer materials such as polyolefins (e.g., polyethylene,polypropylene, polybutylene, etc.), polyesters (e.g., polyethyleneterephthalate), polyacrylamides, polyurethanes, polylactic acids,polyamides (e.g., nylon), polyvinyl alcohol, and any variety ofcopolymers or combinations thereof, where filaments forming one or moreyarns can be mixed filaments having different cross-sectional shapesand/or different combinations of polymer components (e.g., homopolymercomponents or multi-polymer components). The textile layer can furtherbe formed of any one or more combinations yarns having the same orvarying degrees of elasticity. For example, the textile layer can beformed having 2-way or 4-way stretch characteristics. Some non-limitingexamples of elastic or stretchable fabric materials suitable for formingthe outer fabric layer are fabrics comprising one or more combinationsof polyester-polyurethane copolymers referred to generally as elastane(e.g., Spandex or Lycra materials).

In example embodiments, the textile layer 405 can comprise a woven layerformed of yarns comprising a low count of filaments, where the yarnshave a denier in the range from about 20 to about 50 (e.g., a denier ina range from about 20 to about 40, or from about 20 to about 30). One ormore yarns used to form the textile layer 405 can include no more thanabout 25 filaments per yarn, such as from 5 to 25 filaments per yarn, orfrom 5 to 12 filaments per yarn, or even from 7 to 10 filaments peryarn. Thus, the DPF (denier per filament) can range from about 2.0 toabout 4.0, such as from about 2.5 to about 3.5, or from about 2.7 toabout 3.1. The low filament count and low denier yarns result in theformation of a lightweight textile layer having good drape and a softtexture and feel. In addition, the selection of low count filamentyarns, in which the yarns have deniers combined with non-circular shapesas described herein, facilitates the formation of textile structuresthat minimize or eliminate voids within the textile structures which inturn also minimizes and reduces an amount of moisture absorption,trapping and retention within the textile structures.

In further example embodiments, the yarns forming the textile layer 405contain filaments that are non-circular in cross-section so as to reduceor eliminate interstitial spacing, i.e., a number and/or size ofinterstices or voids within the textile layer (e.g., interstices betweenfilaments forming yarns as well as between adjacent yarns within thetextile structure). Such configuration of yarns and filaments formingthe yarns, as well as how the sealing layer is applied to the textilelayer 405 (as described herein) also reduces a number and/or size ofinterstices or voids at a boundary or contact area between the textilelayer and the sealing layer. For example, the filaments can be formedand/or defined within the yarns having non-circular cross-sectionalshapes such as oval or elliptical shapes and polygonal (e.g., threesided, four sided, five sided, etc.) shapes. Filaments that are providedwith a non-circular shape can reduce the interstices therebetween due tothe flatness or less rounded features of the filaments. For example,filaments of a yarn with polygonal shaped cross-sections have flat sidesthat complement each other so as to facilitate greater contact alongadjacent surfaces or even potential interlocking between a plurality offilaments that cannot be achieved utilizing, e.g., round filaments.

Referring to the example embodiments of FIGS. 2A-2D, a cross-sectionalview of a yarn is illustrated in each embodiment that includes sevenfilaments, where the yarn 200A in FIG. 2A includes filaments 202A havinground or circular cross-sectional configurations (such as the filaments515 for conventional yarns 510A, 510B in the fabric material of FIG. 5),the yarn 200B in FIG. 2B includes filaments 202B having triangularcross-sections, the yarn 200C in FIG. 2C includes filaments 202C havingquadrilateral and, in particular, diamond shapes, and the yarn 200D inFIG. 2D includes filaments 202D having elongated round or ellipticalshapes. In each of these figures, interstices may exist betweenfilaments (e.g., interstices 204A between filaments 202A, interstices204B between filaments 202B, interstices 204C between filaments 202C,and interstices 204D between filaments 202D). The yarn 200A includingcircular filaments 202A includes the greatest number of interstices 204Abetween the filaments that define a voids within the yarn. Statedanother way, the void volume of yarn 200A is larger than void volumesdefined by yarns 200B, 200C, 200D s including filaments 204B, 204C, 204Dhaving non-circular cross-sections.

In particular, for polygonal shaped filaments as shown in theembodiments of FIGS. 2B and 2C, at least some of the filaments 202B,202C that are adjacent or neighbor each other can substantially engageand/or interlock along their adjacent flat or substantially planar sidesso as to greatly reduce a void size or substantially eliminate voidsbetween the filaments (i.e., a feature which cannot be achievedutilizing circular filaments). Providing filaments having polygonalcross-sectional shapes in a suitable arrangement with each other allowsfor substantial interlocking and substantial contact betweencomplementary planar surfaces of the filaments so as to substantiallyeliminate or significantly reduce any space or void between adjacentfilaments within the yarn.

Yarns formed from filaments having non-circular cross-sectional shapescan further be substantially flat or ribbon shaped so as to define oneor more generally flat surfaces for the yarns. For example,ribbon-shaped yarns formed with polygonal shaped filaments havingcomplementary and substantially flat or planar sides can be formed withfilaments placed in a side-by-side manner and with suitable orientations(e.g., yarns 200B and 200C as depicted in FIGS. 2B and 2C) so as toengage and/or interlock filaments with adjacent or neighboring filamentsof the yarn. The formation and use of substantially flat or ribbonshaped yarns in turn facilitates a substantial reduction in intersticesdefined between adjacent yarns that form a woven textile or fabric.

The yarns including filaments with non-circular cross-sectional shapescan be formed in any suitable manner. In example embodiments, the yarnsare formed such that their filaments are oriented in a similarlengthwise direction of the yarn but are not twisted together (i.e., notwisting process is required in the formation of the yarns). Thefilaments can be formed via any suitable extrusion process, such as amelt spun process in which molten polymer is extruded though a spinneretincluding orifices having suitable shapes and dimensions to form desiredshapes and sizes of the filaments extruded from the spinneret orifices.The filaments are solidified as they emerge from the spinneret and canbe laid down together on a forming surface to facilitate formation of ayarn of the filaments.

In a specific and non-limiting example embodiment, yarns can be formedcomprising island-in-the-sea (INS) fibers, in which individual “island”polymer components or filaments are formed within a surrounding shell or“sea” polymer component. An example embodiment of an INS fiber thatforms a yarn is depicted in cross-section in the embodiments of FIGS. 3Aand 3B. Referring to FIG. 3A, a ribbon-shaped fiber 302A is formedincluding diamond shaped filaments 202C (e.g., seven filaments) providedas “islands” within a “sea” polymer component 310A. Similarly, an INSfiber that forms a yarn is also depicted in FIG. 3B, where aribbon-shaped fiber 302B is formed including triangular shaped filaments202B (e.g., seven filaments) provided as “islands” within a “sea polymercomponent 310B. Utilizing, e.g., a melt extrusion fiber spinningprocess, INS fibers can be formed having any suitable cross-sectionalshapes (e.g., flat or ribbon shaped, round or circular, etc.) and canalso be formed with any number of filaments having any suitablecross-sectional dimensions and shapes. For example, a spinneret can beprovided with suitable channels and suitably shaped orifices thatfacilitate formation of INS fibers of various types, variouscross-sectional dimensions and shapes, as well as formation of anysuitable number of “island” filaments having various cross-sectionaldimensions and shapes.

The INS fibers can comprise bicomponent or multi-polymer componentfibers, in which the filaments forming the “islands” comprise a firstpolymer component (e.g., polypropylene, PET, etc.) and the “sea” polymercomponent comprises a second polymer component (e.g., polylactic acid orPLA). The second polymer component forming the “sea” is soluble ordissolvable in a particular solvent, while the first polymer componentis substantially insoluble or non-dissolvable in the same solvent.Accordingly, INS fibers that are formed can be treated by exposure to asuitable solvent that dissolves away and removes the “sea” polymercomponent, leaving the “island” filaments intact and in an orientationthat generally corresponds with the layout of the filaments within theINS fiber (i.e., prior to dissolution of the “sea” component). The INSfibers can be combined, e.g., in a weaving process, to form a textile orfabric, followed by dissolution of the “sea” polymer component of theINS fibers, thereby exposing yarns of oriented filaments havingconfigurations such as shown, e.g., in FIGS. 2B and 2C.

The sealing layer 420 can be applied as a coating in any suitable mannerdirectly to a side of the textile layer 405 formed with yarns includingnon-round filaments as previously described herein. In exampleembodiments, a flowable polymer is provided having a viscositysufficient to permit leveling along the textile layer with or withoutthe application of pressure. The flowable polymer may be applied via aknife or blade coating process in which the material is spread over thetextile layer 405, where it is dried, cured and/or solidified to formthe sealing layer 420. Alternatively, the flowable polymer may beatomized and applied as a spray coating to one side of the textile layer405 that dries to form the sealing layer 420. This is in contrast withconventional rain garments, in which a preformed hydrophilic orhydrophobic film is adhered to the textile layer with an adhesive(described in greater detail below).

The flowable polymer may be a fluorine-free material layer that providesa suitable degree of hydrophobicity effective to repel water. An exampleembodiment of a suitable hydrophobic, flowable polymer is polyurethanethat, when applied to the textile layer surface to form the sealinglayer, has a water contact angle of greater than 90°, such as a watercontact angle that is at least about 100°, or a water contact angle thatis at least about 120°.

When applying the coating material (the flowable polymer (e.g.,polyurethane)) to a surface of the textile layer 205 (or any other layerof the garment), the coating layer can be built up in thickness byapplication of the coating material in a series of sublayers orintermediate layers that combine to form the overall sealing layer. Forexample, the coating material can be applied as a liquid or semi-solidto a textile layer, and then spread with a suitable knife blade toachieve a generally level coating layer. The coating material can thenbe dried and/or cured, optionally with heating, to obtain a solid afirst layer in continuous contact with the surface of the textile layer405 and having a thickness of about 1-4 μm (micrometers or microns). Theapplication and spreading process of coating material, followed bydrying and/or curing of the material, can be repeated over the surfaceof the first layer (and each subsequent layer) so as to successivelybuild up or add further material and increasing thickness to the sealinglayer (e.g., in 1-4 micron thickness increments) as many times asdesired to achieve a final desired overall thickness of the sealinglayer that is at least about 10 μm. For example, the operation ofapplying the coating material (as a liquid or semi-solid) and thendrying/curing to solidify the coating material can be repeated aplurality of times, such as three or more times, in order to achieve thedesired thickness of the sealing layer 420.

A suitable application of the hydrophobic polymer material results in asealing layer 420 that has a thickness of about 10 μm to about 30 μm(e.g., about 10 μm to about 20 μm, or from about 10 μm to about 15 μm).In some embodiments, the thickness of the final formed sealing layer 420can vary along a dimension of the composite fabric, where the sealinglayer thickness can vary from about 5 microns in thickness (at the mostthin portion of the sealing layer) to about 30 microns in thickness (atthe largest thickness of the sealing layer), where the average thicknessof the sealing layer can be about 10-20 microns. The variance inthickness of the sealing layer 420 in the composite fabric 400 can bedue to the uneven surface of the textile layer 405 to which the sealinglayer is coated. In some embodiments, the yarns forming the textilelayer 405, such as a woven textile layer, can form an uneven orundulating surface that results in depressions or valleys and bumps orhills along the textile layer surface (e.g., as a result of theoverlapping between warp and weft yarns of the woven textile structure).

By providing the sealing layer as a built-up coating (e.g., built up byknife coating in a plurality of intermediate coating layers) on thetextile layer to form the composite fabric, the sealing layer providessignificant coverage against the surface of the textile layer so as tosubstantially contact the textile layer surface and prevent orsubstantially minimize voids between the sealing layer and the textilelayer. As previously noted, certain types of textile layers can haveuneven surfaces due to the texture of the formed textile. This can bebased upon how the textile layer is formed. For example, a woven textilelayer is defined by intersecting warp and weft yarns, which can resultin an uneven, undulating surface for the textile layer. This can also bebased upon the types of yarns used and the yarn compositions (e.g.,deniers of yarns and filaments forming the yarns). The sealing layerformed as a coating and at a sufficient thickness (e.g., a thickness ofat least about 10 μm) over the textile layer will result in the coatingmaterial filling in and making continuous contact with (i.e., conformingwith the contour of) all uneven surface area portions of the textilelayer so as to eliminate or substantially minimize or reduce spaces orvoids between the sealing layer and the textile material. This is insignificant contrast to a preformed film layer that is applied to atextile layer (e.g., via a dot lamination or other adhesion process), inwhich the substantially planar film (unlike the coated WP layer of thecomposite fabric described herein) cannot conform with the unevencontour of the textile layer such that spaces and voids exist betweenthe two layers. By eliminating or significantly reducing void volumebetween the sealing layer 420 and the textile layer 405 of the compositefabric, water retention within the garment incorporating such compositefabric material will be significantly diminished in comparison to twolayer fabric structures that incorporate a preformed film.

An example embodiment of a composite fabric 400 for use as part of anarticle of apparel is depicted in FIGS. 4A, 4B and 4C. In particular, aportion or section of a two layer composite fabric 400 is shown incross-section in each of FIGS. 4A, 4B and 4C (magnified at varyingdegrees, with the greatest magnification provided in the view of FIG.4C). Portions of the jacket 102 (FIG. 1), including section 150, cancomprise the composite fabric structure as depicted in FIGS. 4A-4C. Asshown, the composite fabric 400 includes a woven textile layer 405comprising intersecting yarns (e.g., warp yarns 410A and weft yarns 410Bthat form the woven textile layer), where each yarn is flat or ribbonshaped and comprises non-round (e.g., diamond-shaped) filaments 412.Each yarn 410A, 410B includes about 7-10 non-round filaments 412. Asealing layer 420 (e.g., a polyurethane layer) is provided along oneside of the woven textile layer. The composite fabric 400 is implementedwithin an article of apparel or garment (e.g., at section 150 of thejacket 102 of FIG. 1) such that the sealing layer 420 forms or definesthe interior or wearer facing side of the article of apparel.

As can be seen, e.g., in the photographic image of FIG. 4C, the weftyarn 410B includes seven filaments 412A, 412B, 412C, 412D, 412E, 412F,412G, with adjacent filaments being laterally positioned or stacked (oneon top of another). As shown, voids or interstices 440 are presentbetween some filaments 412A, 412B, 412C, 412D, 412E, 412F, 412G whilesubstantially nonexistent between other filaments. With thisconfiguration, the overall void volume of the textile 405 is minimized,being lower compared to a yarn including circular filaments or otherfilaments that do not interlock.

In addition, along the boundary 450 of the textile layer 405 and thesealing layer 420, little to no interstices or voids exist because theflowable material forming the sealing layer 420 has contoured to thetopography of the textile layer 405. Stated another way, the relativelyflat surfaces of the yarns 410A, 410B as well as the coating process forapplying the sealing layer 420 to the textile layer 405 also minimizes,reduces or substantially eliminates gaps, interstices or voids 440between the sealing layer 420 and the surface of the textile layer thatis adjacent the sealing layer.

The substantial reduction or elimination of interstices or voids withinthe textile layer as well as at a boundary 450 between the textile layer405 and the sealing layer 420 significantly minimizes or preventscapturing, trapping and retention of moisture within the two layercomposite fabric structure that might otherwise occur. Despite the factthat the woven textile layer defined by intersecting yarns 410A, 410Bhas an uneven or undulating surface, the sealing layer 420 (by nature ofit being coated onto the textile layer) substantially conforms to theuneven contour of the overall textile layer surface (as evident in themagnified view of FIG. 4C) such that little or no space exists betweenthe two layers. In other words, an amount of water that may be trappedby the voids in the textile layer 405 along the boundary 450 of thetextile layer 405 and the sealing layer 420 is reduced as a result of areduction in spaces or interstices as well as overall or total voidvolume within the composite fabric structure due to the configuration ofthe textile layer and the sealing layer as applied to the textile layer.Contrast this, e.g., with a conventional two-layered structure includinga preformed film layer laminated to a textile layer as depicted in FIG.5, where interstices or voids are clearly present to a much greaterdegree within the conventional two layer structure and thus define amuch greater void volume within the two layer structure in comparison tothe composite fabric 400 of FIGS. 4A-4C.

Stated differently, this is in contrast with conventional waterproofgarments (e.g., rain gear) in which a two layer structure is formedincluding an outer textile layer and an inner, preformed film layeradhered to a surface of the textile layer via an adhesive, typically dotlamination or other similar process. The reason for providing thepreformed layer as a film is that a film of a certain thickness istypically less porous than a coating of a similar thickness andtherefore is better at reducing the penetration or pass through ofmoisture through the preformed film layer. However, the preformed filmlayer is typically thick (e.g., greater than 30 micrometers inthickness) and can make a garment bulky and heavy (due to the weight ofthe adhesive and film), but can also increase the interstices or gapspresent along the boundary between the film and the textile. These gapsserve as cavities that capture water, further weighing down the garmentand increasing dry time.

An example embodiment of a conventional garment including a textilelayer and a preformed film layer is depicted in the magnifiedphotographic image of FIG. 5. The garment 502 has a two layeredstructure including a woven textile layer 505 comprising woven warpyarns 510A and weft yarns 510B. A preformed film 520 laminated to oneside of the textile layer 505. The film 520 is secured to the textilelayer 510 via a dot lamination process, where lamination dots 530 arespaced from each other in any suitable arrangement or pattern tofacilitate adhering of the preformed film to the textile layer. Thespacing between the lamination dots 530 results in interstices or voids540A along the boundary 550 of the preformed film layer 520 and yarns510A, 510B of the textile layer 505, and these voids can collect andretain water that penetrates either layer. In addition, the yarns 510A,510B include a plurality of filaments 515 (e.g., more than 30 filamentsper yarn) having cross-sectional shapes that are generally rounded orcircular. The filaments 515 of each yarn 510A, 510B also combine in amanner that results in interstices or voids 540A within the yarn. Thesevoids 540B between filaments 515 of yarns 510A, 510B as well as thevoids 540A between the preformed film layer 520 and the textile layer505 can result in the garment retaining water and taking a significantamount of time to dry (i.e., to evaporate moisture that exists withinthe voids). In addition, even when a preformed film is adhered in somemanner other than using lamination dots, there can still be significantvoids that exist between the generally flat and planar surface of thefilm that contacts an uneven (e.g., undulating) surface of the textilelayer to which the film is secured. For example, in a scenario in whichthe textile is woven (such as depicted in FIG. 5), the surface of thewoven textile is uneven due to the crossing warp and weft yarns locatedat the surface, such that the flat surface of the preformed film thatengages with a corresponding surface of the woven textile layer hassurface portions that do not continuously contact the surface of thewoven textile resulting in spaces or voids defined therebetween.

It has been determined that providing a sealing layer at a thickness ofat least 10 microns (or an average thickness of about 10-20 microns fora sealing layer that varies in thickness), in combination with a textilestructure including low filament count yarns having non-circularfilaments, such as polygonal filaments results in a lightweightstructure for incorporation, e.g., in a garment or other article ofapparel. In particular, it has been determined that a sealing layerhaving a sufficient thickness of at least about 10 microns effectivelyrepels water from the garment surface and prevents or substantiallyminimizes water penetration or pass through when exposed to rainy orother wet environments. However, the sealing layer should be limited tohaving a thickness of no greater than about 30 microns, since anygreater thickness would diminish desirable features such as thelightweight properties of the garment, its drape, hand and feel andwould further increase the production costs for the garment. Inaddition, increased water repellency is not achieved over thisthreshold. A garment such as a jacket that incorporates the compositefabric structure as described herein is suitably lightweight, hassuitable waterproof (WP) characteristics, dries quickly after exposureto water (e.g., exposure in a rainy environment) due to its low waterretention properties, and can be easily folded or rolled up for storage(e.g., placement in a backpack, purse or other suitable carrier) whennot being worn.

Tests were conducted to determine the effectiveness in relation to waterrepellency as well as water retention of the composite fabric structure400 as described herein in comparison to other, conventional waterproofgarments.

Water Repellency Effectiveness of Composite Fabric Structure

Tests were conducted for the composite fabric structure to determine itsability to provide effective water resistance against water penetratingthe composite fabric structure when subjected to typical rainenvironment conditions. The tests were conducted utilizing a compositefabric including the same textile layer (formed as a woven textile withyarns including 5-25 quadrilateral or diamond shaped filaments) and witha sealing layer coated on the textile layer at different thicknesses.For example, sealing layer thicknesses were modified based upon a numberof times a coating material (the flowable, hydrophobic polymer) wasapplied via a knife coating process to the textile layer 405 to build upthe sealing layer 420 to a desired thickness. A single coatingapplication results in a sealing layer having an average thickness ofabout 2-4 microns, whereas a double coating application results in asealing layer having an average thickness of about 4-7 microns, and attriple coating application results in a sealing layer having an averagethickness of at least 10 microns.

A hydrostatic pressure test was performed under SGS-IPS Standard AATCC127. This test measures the resistance of a fabric material to thepenetration of water under hydrostatic pressure (where the hydrostaticpressure is determined at failure or initial pass through of waterthrough the fabric material). A typical wind driven rainstorm canprovide a hydrostatic pressure of about 2 psi. The composite fabricformed with a sealing layer having a thickness of at least 10 micronsshowed water resistance (i.e., prevention of water passing through thecomposite fabric) at a hydrostatic pressure of about 3 psi (about 2100mm in water depth). Lower thickness levels for the sealing layer 420 arenot as effective against water penetration (i.e., are not consideredwaterproof under AATCC 127).

In addition, a Bundesmann Water Repellency/Rain Shower Test wasperformed on each fabric structure. The Bundesmann test utilizes anapparatus that simulates a rainstorm by showering water from a pluralityof nozzles onto a test fabric material located within a compartment orhousing of the apparatus. The test fabric material can be provided overa container to measure an amount of water that passes through the fabricmaterial during the test. Test specimens were subjected to theBundesmann test within the apparatus for a test period of about 10minutes. From the Bundesmann test, it was determined that the sealinglayer 405 having a thickness of at least 10 microns did not allow anywater to pass through the fabric material (no water was present withinthe container underlying the test specimen). It was further determinedthat the fabric material formed with a sealing layer 420 having anaverage thickness of 2-4 microns (single pass material coating) had somewater pass through the material (as determined by water present withinthe container), while the fabric material formed with a sealing layer420 having an average thickness of 4-7 microns (double pass materialcoating) had a small amount of moisture pass through (determined by asmaller amount of moisture within the container).

Water Retention Effectiveness of Composite Fabric Structure

A series of tests were conducted to determine the effectiveness in waterretention for the composite fabric structure as described herein.

Test 1

Samples of a composite fabric structure of the type depicted in FIGS.4A-4C were tested and compared with other two layered fabric structures.The composite fabric structure included a textile layer formed withyarns comprising 5-25 quadrilateral or diamond shaped filaments and apolyurethane sealing layer coated onto the textile layer at an averagethickness of about 10 microns. For comparison purposes, a two layerstructure that includes a preformed film layer laminated to a textilelayer that includes yarns having round filaments, as depicted in FIG. 5,was also provided.

A Bundesmann Water Repellency/Rain Shower Test was performed on eachfabric structure. Test specimens were subjected to the Bundesmann testwithin the apparatus for a test period of 10 minutes. Each test specimenwas weighed before and immediately after the Bundesmann test todetermine an amount of water retention (based upon a weight difference).

As a result of the test, the composite fabric structure of FIGS. 4A-4Chad a weight increase of 7.6% due to water absorbed and retained withinthe two layer structure. The two layer structure of FIG. 5 had a weightincrease of 46.3%, indicating a much greater amount of water retentionwithin the structure (i.e., due to the larger void volume defined withinthis two layer structure).

Test 2

A composite fabric test sample having a similar configuration as thatdepicted in FIGS. 4A-4C (woven textile with yarns having diamond shapedfilaments with 5-25 filaments per yarn) was compared with other twolayered fabric material test samples as follows: Sample A included atextile layer similar in configuration as the textile layer for thecomposite fabric, and a preformed hydrophobic layer of at least about 20microns laminated to the textile layer; and Sample B included a textilelayer similar in configuration as the textile layer for the compositefabric, and a preformed hydrophilic layer of at least about 20 micronslaminated to the textile layer.

The test was conducted for each sample by submerging the sample in abath of soapy water for a time period of 5 minutes. Each sample was dryweighed before the test, followed by weighing the sample wet after beingwithdrawn from the bath. A number of specimens of each sample type weretested, and the test results (based upon an average of the number ofspecimens for each sample type) are as follows:

Test Results

Sample Dry Weight (g) Wet Weight (g) Wet Pick-Up (%) Composite Fabric0.0814 0.1277 56.93 Sample A 0.2045 0.3734 82.54 Sample B 0.1905 0.4506102.45

The test results indicate that the composite fabric retains less water(indicating a lower void volume) in relation to the test samples thatinclude a preformed layer.

Thus, the structural configuration for the composite fabric as describedherein provided enhanced water resistance/waterproofing properties foran article of apparel (e.g., a rain jacket) in relation to otherconventional articles of apparel. In particular, the textile layerincluding low filament count yarns with non-circular (e.g., polygonalshaped) filaments and a sealing layer that is coated over the textilelayer reduces overall void volume of the composite fabric, thusminimizing water retention within the article of apparel when subjectedto rain conditions. In addition, the sealing layer having a thickness ofat least about 10 microns and not greater than about 30 micronssufficiently minimizes water pass through under typical rain conditions.Articles of apparel formed with the composite fabric exhibit suitablewaterproof properties and minimal water retention (resulting in a rapiddrying time after exposure to moisture), suitable lightweightproperties, and a desired hand, drape and feel to the article ofapparel. It is intended that the present invention covers themodifications and variations of this invention provided they come withinthe scope of the appended claims and their equivalents. For example, thearticle of apparel (or a portion thereof) can include more than twomaterial layers (e.g., 2.5 layers, 3 layers, etc.). By way of specificexample, a mesh liner or scrim layer (e.g., a very lightweight andporous fabric layer having a basis weight that is less than the basisweight of the textile layer) can be provided as an interior layer forthe article of apparel. Further, any one or more layers can be providedalong either side of the textile layer and/or the sealing layer thatfaces away from the boundary between the two layers. Further still, oneor more layers can also be provided between (and thus located within theboundary between) the textile layer and the sealing layer.

The textile layer and any other material layers defining an article ofapparel (or a portion thereof) can have a thickness that is on the orderof micrometers or microns (e.g., no greater than about 100 microns),millimeters (e.g., no greater than about 100 millimeters) or evengreater thicknesses.

As noted herein, the garment of the present invention significantlyreduces or minimizes penetration and absorption of water within thegarment while also ensuring adequate waterproof (WP) protection in highhumidity/raining environments and further being substantiallylightweight with desirable drape.

It is to be understood that terms such as “top,” “bottom,” “front,”“rear,” “side,” “height,” “length,” “width,” “upper,” “lower,”“interior,” “exterior,” “medial,” “lateral,” and the like as may be usedherein, merely describe points of reference and do not limit the presentinvention to any particular orientation or configuration.

What is claimed:
 1. A rain jacket including arm sleeve sections and atorso section, the rain jacket comprising a composite fabric, whereinthe composite fabric comprises: a textile layer comprising a pluralityof yarns, each yarn including five to twenty five filaments, and eachfilament having a cross-sectional shape that is non-circular; and asealing layer applied as a coating directly to the textile layer andhaving a thickness of about 10 micrometers to about 30 micrometers. 2.The rain jacket of claim 1, wherein the filaments of the yarns formingthe textile layer have the same polygonal shape.
 3. The rain jacket ofclaim 1, wherein each yarn includes 5 to 12 filaments.
 4. The rainjacket of claim 1, wherein each yarn includes 7 to 10 filaments.
 5. Therain jacket of claim 1, wherein each yarn has a denier ranging fromabout 20 to about
 50. 6. The rain jacket of claim 1, wherein each yarnhas a denier ranging from about 20 to about
 30. 7. The rain jacket ofclaim 1, wherein the denier per filament of each yarn ranges from about2.0 to about 4.0.
 8. The rain jacket of claim 1, wherein the denier perfilament of each yarn ranges from about 2.7 to about 3.1.
 9. The rainjacket of claim 1, wherein the sealing layer comprises polyurethane. 10.The rain jacket of claim 1, wherein the sealing layer is free offluorine.
 11. The rain jacket of claim 1, wherein the sealing layer isapplied as a coating so as to continuously contact a surface area of thetextile layer.
 12. The rain jacket of claim 1, wherein the sealing layerforms an interior surface of the rain jacket so as to face a userwearing the rain jacket.
 13. A method of forming a composite fabricstructure, the method comprising: applying, via a coating process, aliquid or semi-solid material to a surface of a textile material so asto form a solid material sealing layer directly on the textile materialsurface having a thickness of about 10 micrometers to about 30micrometers; wherein the textile material comprises a plurality ofyarns, each yarn including five to twenty five filaments, and eachfilament has a cross-sectional shape that is non-circular.
 14. Themethod of claim 13, wherein each filament of the yarns forming thetextile layer has a cross-sectional shape that is polygonal.
 15. Themethod of claim 13, wherein the applying via a coating processcomprises: (a) spreading the liquid or semi-solid material over thesurface of the textile material; (b) drying the liquid or semi-solidmaterial spread over the textile material surface to form anintermediate coating layer having an intermediate thickness that is lessthan 10 micrometers; and (c) repeating steps (a) and (b) to increase athickness of the solid material until forming the sealing layer of solidmaterial having a thickness of about 10 micrometers to about 30micrometers.
 16. The method of claim 15, wherein steps (a) and (b) arerepeated a plurality of times.
 17. The method of claim 13, furthercomprising forming the textile structure by: forming islands-in-the-seafibers, wherein the filaments are formed within a sea polymer component;and removing the sea polymer component from the non-circular filamentsto form yarns comprising the filaments.
 18. The method of claim 17,wherein each yarn is formed with 5 to 12 filaments.
 19. The method ofclaim 17, wherein each yarn is formed with 7 to 10 filaments.
 20. Themethod of claim 13, further comprising incorporating the compositefabric structure into a rain jacket.